3DCS FEA Compliant Modeler Add-on integrates Finite Element Analysis (FEA) into the 3DCS tolerance analysis platform. It enables simulation of flexible materials and parts affected by manufacturing processes such as welding, clamping, bolting, and riveting. This add-on enhances traditional rigid-body modeling by accounting for deformation due to physical forces and environmental conditions, providing a more accurate prediction of product variation.

Features

• FEA Integration
• Combines traditional tolerance analysis with FEA to simulate the impact of clamping, force, gravity, and heat on parts.
• Material Behavior Simulation
• Models how materials like aluminum, rubber, and plastics react to forces, including stretching, sagging, and deformation.
• Process Simulation
• Simulates manufacturing processes such as welding, riveting, and bolting to assess their impact on dimensional quality.
• Thermal and Gravity Effects
• Applies environmental and operational heat, as well as gravity, to analyze their influence on part deformation.
• Clamping and Assembly Sequences
• Tests different sequences of clamping and joining to determine optimal order for minimizing variation.
• Over-Constrained Assemblies
• Evaluates how pressure, force, and tooling constraints affect dimensional integrity.
• AAO Add-on Compatibility
• Works with the 3DCS AAO Add-on to optimize operation sequences and reduce simulation time.

Benefits

• Enhanced Accuracy
• Provides more realistic simulation results by modeling flexible part behavior under real-world conditions.
• Process Optimization
• Identifies the best order of operations and placement of clamps or welds to reduce variation and improve quality.
• Cost Reduction
• Minimizes the need for physical prototypes and rework by predicting issues early in the design phase.
• Improved Product Quality
• Accounts for deformation and springback, leading to better control over final product dimensions.
• Design Validation
• Validates how design and material choices respond to manufacturing forces, enabling informed decision-making.
• Time Savings
• Reduces manual calculations and accelerates simulation with configurable tools and algorithms.